Magnetic testing apparatus



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July 8, 1947. J. E. CLARKE MAGNETIC TESTING APPARATUS Original Filed Sept. 10. 1941 e sheets-sheet e NNY Patented July 8, 1947 2,423,552 MAGNETIC TESTING APPARATUS I `lohn E. Clarke, Chicago, Ill., assignor to Magnafiux Corporation, Chicago, Ill., a corporation of Delaware Griginal application September 10, 1941, Serial No. 410,334. Divided and this application May 28, 1942, Serial No. 444,780

(Cl. F75-183) 7 Claims.

This invention relates to magnetic testing apparatus and more particularly to a magnetizing prod and energizing system therefor, including 'novel switch means and switching system.

In general, the apparatus to which this invention relates is employed in magnetically inspecting paramagnetic objects for fissures, cracks, and other structural defects. It is particularly applicable in the testing of Welds for voids, shrinkage cracks and lack of fusion, and in testing of large areas such as edges of thick plates for the type of defect frequently spoken of as laminations or inclusions of non-magnetic material which have been rolled out in such a manner as to present themselves as definite magnetic discontinuities at the exposed surface.

This invention is a division of my co-pending application for Magnetic testing apparatus and methods of magnetizing, United States Serial No, 410,334, filed September 10, 1941, now United States LettersPatent No. 2,352,371, and assigned to the same assignee as the present invention.

It is an object of the present invention to provide a novel switching system for magnetic testing apparatus and particularly magnetic testing apparatus which includes a magnetizing prod which is arranged to engage the object to be tested to cause current to flow through the latter.

It is a further object of the present invention to provide a novel switch means for magnetic testing apparatus and particularly for a magnetizing prod.

It is a still further object of the present invention to provide a novel handle switch in a magnetizing prod.

Another and further object of the present invention is to provide novel switching means for a magnetizing member.

Another and still further object `of the present invention is to provide novel magnetic testing apparatus and means for energizing the same.

Still another and further object of the present invention is to provide magnetic testing apparatus having novel means for connectingr and disconnecting a current carrying contact element with a, source of power,

It is an object of this invention to provide magnetic testing apparatus having switching means therein for sending direct current having controllable ripple component through the object to facilitate movement of the finely divided paramagnetic particles on the object into a dening pattern.

It is a further object of this invention to provide novel magnetic testing apparatus having switching means therein to initially magnetize the object by a surge of current of one intensity for a short period of time to produce a relatively high flux density ln the object and to then subsequently reduce the magnetizing current to substantially lower intensity for the period of inspection, so that the object will not become unduly heated, and so that a relatively high iiux density obtains in the object during the period of current iiow at reduced intensity, as compared with what the iiux density would have been had the object been initially magnetized by current not exceeding the reduced value of current.

It ls a further object of this invention to prolvide novel contact prods for magnetic testing apparatus.

The novel features which I believe to be characteristic of my invention are set forth with particularity in the appended claims. My invention itself, however, both as to its organization and manner of construction, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in connection with the accompanying drawings, in which:

Figure 1 is a diagrammatic showing of circuits and instrumentalities embodying the invention and with a terminal shown partly in section and kpartly in plan.

Figure 2 is a sectional view of a modified terminal portionwith a part in plan.

Figure 3 is a sectional view of a modified terminal connection with a part in plan.

Figure 4 is a curve illustrating the relation between magnetizing force and flux in a specimen of material,

Figure 5 is a curve showing the output current of a three-phase full-wave rectifier under balanced phase voltage conditions.

Figure 6 is a curve showing the output current of a three-phase full-wave rectiiier under unbalanced phase voltage conditions.

Figure '1 illustrates a portable power source with parts in plan and parts indicated by dotted lines.

Figures 8, 9, 10, 11 and 12 are diagrammatic showings of modified arrangements of circuits and instrumentalities embodying the invention.

One embodiment of the invention is shown diagrammatically in Figure 1, in which a source of alternating current comprising three-phase power lines I0 is connected through a circuit breaker Il to two auto-transformers I2 and I3 provided with winding taps, indicated at I4 and l5, respectively, and with tap switches IB and I1, for supplying power to a three-phase bank of transformers I8, I9 and 2U, respectively. The primary windings of the transformers are connected by line leads 2l, 22, and 23 through choke coils 24, 25 and 26 to the middle leg of the power supply and to the tap switches, so that there is a choke coil in each leg of the threephase supply, and so that there are means for selectively varying the voltage impressed on the transformers in two of the phase leads. The secondary windings of the transformers are connected to a group of rectifiers, indicated generally at 21, in the manner shown, to provide a full-wave rectication. The rectifiers are of the copper-oxide type, or of any other conventional dry type.

Heavy current flexible leads 28 connect the output side of the rectifier bank with a contact prod, indicated generally at 29, for connection to a specimen, indicated generally at 3l), for magnetization of the specimen by current therethrough.

'- The contact prod 29 may be formed of a steel shell 3| to which a handle 32 is secured. The inner face ofl the shell 3| is suitably covered with insulation as indicated at 33, and the shell is provided with an end cap 34 of insulating material. A reciprocable rod 35, of copper or the like, is housed in the shell 33, and is normally pressed outwardly by a spring 36. A lug 31 on the rod is connected to the lead 28.

Within the shell there is a pair of `contact elefments 38 to form an auxiliary switch 39, and one of the contacts is carried on the shell in insulated relation thereto, and the other is carried by the rod 35 in insulated relation thereto. When the contacting end 40 of the rod 35 is pushed against the specimen 30, inward movement of the rod will result in engagement of the contacts 38, and

conversely, a force less than that necessary to overcome the outward push of the spring 36 will result in opening the switch 39.

vThe contacts 38 form an auxiliary switch 39 controlling the three-phase supply to the transformer bank so that the power supply will be interrupted before the contact 40 leaves the specimen, and so avoid arcing and burning of the specimen and of the contact point 40. The contacts 38 are connected in series with Wires 4l and 42 and in series with a solenoid 43 to actuate the circuit breaker Il, and the circuit is fed by the secondary 44 of a small isolating transformer 45 which has its primary 4S connected to the power supply by wires 41 through a switch 48.

It will now be evident that any intentional or `accidental decrease in substantial amount of the force with which the prod is applied to the specimen will result in the de-energizing of the solenoid 43 and the opening of the circuit breaker Il. Thus, the circuit is opened on the highvoltage low-current side, where it can be readily interrupted by a high-speed circuit breaker, and use of the contact point 40 as a circuit breaker is avoided.

The contact prod may also take the form shown `in Figure 2, in which a normally open switch 49 employed, as shown in Figure 3. In this modified form, the prod 55 is housed in an insulating housing 55 within a steel protective housing 51 which has a handle 58 secured thereto. A cable 59 is carried through the handle to a stationary contact 60 in the insulating housing, and another contact 6I carried by the prod is adapted t0 engage it when the prod is pushed against the specimen in opposition to a spring 62 in the housing 56. The contacts 60 and 6| may be of silver, or other suitable material.

The choke coils 24, 25 and 26 are normally short-circuited by a circuit breaker indicated generally at 63. This circuit breaker 63 is arranged to be opened upon the energization of its operating solenoid 64, which is connected to the lines 4I and 42 through a timing switch 65 controlled by the auxiliary switch 39 of the prod. The timing switch is shown as provided with a dash-pot B6 having a control valve 61 for ease in illustrating a delayed action switch, but other conventional forms of relays or switches, such as the induction type of relay with time setting, may readily be employed to insert the choke cils in the circuit at a predetermined time following the closing of the auxiliary switch 39.

The power supply voltage to the transformers i8, I9 and 20 is adjusted so that when the choke coils are short-circuited and in effect out of the circuit, there will be -an abnormal, although intended, surge of direct current from the rectifiers and through the specimen to be magnetized, and this current of relatively high intensity is maintained. for a predetermined time until the choke coils are made effective to reduce the magnetizing current in the specimen to a. lower and sustained value during the inspection of the magnetized specimen.

A sustained current of high density in the specimen would result in undue heating of the specimen and relatively high power loss, and a sustained current of high intensity in the leads causes troublesome magnetic leakage and interference with inspection of the magnetized specimen when paramagnetic particles, indicated at 68, are applied to the specimen to detect defects in the specimen.

When the current is sent through the specimen to magnetize it for inspection, the total eld in the space occupied by the specimen under inspection isy the result of the field due to the iron of the specimen and that due to the current flow through the specimen.

The field due to the specimen being inspected by the use of paramagnetic particles is, of course. the desired portion of the total field. We must have current in the conductors feeding this portion, but we can increase the sensitivity of the inspection method for discovering cracks and flaws in the inspected portion of the specimen if we can reduce the disturbing effect of the currents in the conductors, so that the eld due to the specirnen itself is the major factor in determining the pattern to be taken by the paramagnetic particles.

In the method of magnetizing the specimen according to the present invention, the specimen is initially subjected to a surge of current of abnormally high intensity for a brief period to subject the specimen to an abnormally high magnetizing force and produce an abnormally high value of flux, and subsequently the current is reduced to and maintained at a lower and normal value, but the flux in the specimenbecause of the specimen having been subjected to the surgeis greater than that initially possible with an initial application of the reduced value of current. The inspection; therefore, can be carried out with a iiux condition in the iron adequate for inspection purposes, and yet with a relatively low value of current in thefconductors.

In further explanation of the method, Figure 4 is now referred to. In the hysteresis curve shown for the purpose of illustration, the curve OA indicated generally the relationship between B and H for hard steel magnetized by current through it, if we assume that the specimen had no initial magnetism. If we let the line OF represent the value of H, the magnetizingforce due to the current, on the normal induction or virgin curve, the line OK represents the consequent value of B, the magnetic flux.

If we again start from zero flux, but increase the value of H to correspond to the line OG, the flux value now becomes OM. Having reached the magnetizing force of value OG, if we now decrease the current to again represent a magnetizing force value of OF, we find that the flux is now of a value represented by the ordinate OL, a value much higher than obtained from the normal current working along the virgin curve line.

When the contact prods are applied to the specimen to result in the closing of the auxiliary switch 39 and the closing of the switch I i by the solenoid 43, the initial magnetizing current through the specimen is abnormal for a period long enough to enable the circuit to reach a substantially steady state condition, and not long enough to injure the specimen by overheating.

Residual magnetism is generally very low in the specimen as it comes from the lathe or forge to the inspection bench, and it is a simple matter for the inspector to adjust the power supply voltage to make certain of a current surge to overcome or augment the residual and give a satisfactory value of flux for inspection purposes when the current is reduced to normal at the end of the surge period.

When a three-phase source is used to supply a bank of full-wave rectifiers, the direct current output is fairly smooth, as indicated by the heavy current line 69 of Figure 5, where it is assumed that there is no smoothing effect due to inductance and the voltages from the transformer secondaries are sinusoidal and equal. A multiphase source of A. C. voltage is usually employed to obtain smooth D. C. output, and although a three-phase input has the advantage of a balanced loading of the phases, the prime reason for the three-phase input is the smooth D. C. output.

In the method of magnetizing the specimen according to the present invention, the threephase input is employed for the several advantages inherent in providing a three-phase load, but means are employed to obtain a D. C. output having pronounced ripple of desired characteristics, for in doing so it has been found that para.- magnetic particles on the specimen are lively" and readily distribute themselves over the inspection zone to produce a satisfactory pattern for inspection purposes.

The specimen is subjected to a pulsating direct current, and in circuit analysis it is convenient to think of this current as made up of a constant direct current plus a superimposed alternating current of a determinable frequency and wave shape. In this way the effect of incremental permeability of the specimen due to the ripple component can be more readily determined.

In Figure 6 thereis shown the approximate result of supplying the transformer bank with voltages of normal value, half of normal value and 86% of normal value, respectively, .on .the phases, so that the direct current ouput of the rectifiers to the leads 28 is approximately that indicated by the heavy line 10.

The unbalancing of the phase voltages is obtained by adjusting the positions of the `tap switches I6 and I1 to produce any desired amount of ripple in the direct current output of the rectiers. l

The transformers may, of course, be designed to produce a desired ripple due to certain transformers of the bank having abnormal performance characteristics compared with others of the bank either in the magnetic loading ofthe iron or in the regulation under load characteristics. However, the tap switches and auto-transformer arrangement shown enables one to readily control the ripple for most satisfactory control of the inspection procedure, particularly so when it is remembered that the specimens vary widely in size, shape, and material in routine inspection in the factory.

The tap switches maybe initially adjusted es to position and then coupled together for voltage control by a single operating handle,

As is indicated in Figure 7, the choke coils, rectifiers, switches, meters, and indicating lamps are all mounted as a unitary structure in a casing 1I mounted on casters 12 as a portable unit for moving about the factory.

The surge current may be as high as 6,000 amperes in the testing of certain types of specimens of large size, but surge current values of around 1200 amperes are commonly used in factory inspection work.

For certain situations a surge-producing arrangement shown diagrammatically in Figure 8 oicrs advantages.

In Figure 8, the specimen, indicated at 13, is shown as connected by the contact prods 1l and by wires 15 and 16 to .a suitable source of direct current 11 through the secondary 18 of a transformer 19 and a magnetic switch 80 having an operating solenoid 8| and an armature 8l.

It is intended that upon the closing of the direct current circuit a surge voltage will be set up in the secondary 18 of the proper sign to momentarily increase the direct current through the specimen.

To obtain this surge voltage superimposed on the voltage of the direct current source, a rectifier tube 83 is supplied with energy from a transformer 84 to charge a condenser 85 connected in series with the primary 86 of the transformer 19. through a current-limiting resistor 81. One end of the primary B6 is connected to the cathode 88 of 'an electron tube 89. The grid 90 of the tube 89 is suitably connected to the tube 83 in a conventional manner for a high negative bias, so that the tube 89 is normally an open circuit across the ends of the circuit including the wires 9| and 92 and the winding 86 and the condenser` 85. The operating coil 8| is connected to the alternating current supply leads 93 by wires 95 and an auxiliary switch 94, which may be on one of the prods in the manner already disclosed in the description of the prod 29 of Figure l, and when the armature 82 moves to close the switch 80, it also closes a switch 98 which connects the Wire 92 with a wire 91 to remove the bias on the grid 80. This permits an arc to pass from the 'I'he condenser 85 is fed by the tube 83A switch 96 and the ring of the tube 8B.

In a modication shown in Figure 9, a source Y of direct current indicated generally at |00 is connectible by the Contact prods to the specimen |02 through a circuit including a pair of wires |03 and |04, a magnetic circuit breaker |05, and a magnetic switch |06 which normally short-circuits a resistor |01.

When the prods |0| are pushed against the specimen and an auxiliary switch |00 is closed,

Ythe closing of the auxiliary switch results in the closing of a`circuit including the source, the switch, wires |09 and ||0, and an actuating solenoid of the circuit breaker |05.

With the closing of the circuit breaker |05 there is an initial current of high intensity allowed to flow for a predetermined period of time until the switch |06 opensito insert the resistor |07 inthe circuit a'nd condition the circuit for a maintained current of relatively low intensity during the period of inspection. To effect opening of the switch |06, a magnet ||2 is energized by current flow through the wire |04 to close a switch l I3 connecting the source to the actuating solenoid ||4 of the switch |05 through a delayed action relay ||5 by wires ||5 and As is best shown vin Figure l0, a modification of the arrangement shown in Figure 8 may be employed, and in this modification a condenser ||8 is charged by some source of suitable Voltage, such as a direct current generator ||9, through a resistor |20. The specimen to be magnetized, indicated at |2|, is connectible to a direct current source, indicated at |22, through Contact prods |23 and a secondary winding |24 of a transformer |25 by wires |26 and |21. The condenser ||8 is in a circuit which comprises a primary winding |28 of the transformer, a relay |29, and connecting wires |30 and |3|. A resistor |32 may be interposed in the circuit to make it substantially aperiodic.

It will now be evident that when the contact prods are initially connected to the specimen, current from the source will immediately energize. the relay |29 to close its contacts and to result inthe discharging of the condenser through the winding |28 to set up an impulse of voltage in the winding |24 t0 momentarily increase the current through the specimen. A choke coil |33 may be inserted in series with the generator to more effectively isolate the condenser from the generator at the moment of discharge. A switch |34 may be inserted in the condenser circuit to interrupt it when desired. The resistor |20 is designed for the conventional purpose of charging the condenser at a relatively slow rate, and the constants of the condenser circuit are designed so that there is a substantial increase of current for a suthciently long period through the specimen while the condenser is discharging.

Figure l, and toadopt the modification shown in Figure l1. In'Figure 11, some suitable form of main switch |35 is interposed in the power lines |36, and the power lines feed rectiers |31 through transformers |38 and through choke coils |39. The choke coils are normally shortcircuited by a switch |40 which has an operating solenoid |4| and suitable time-delay means, indicated at |42 by a conventional dash pot arrangement. When contact prods |43, connected to the rectiers by wires |44, are connected to the specimen |45, a relay |40 responsive to current in the Wires |44 closes its switch |4`| to energize the solenoid |4| through wires |48 and |49 connected to the power lines. A switch |50 may be interposed in the solenoid circuit to be opened at will.

The main switch |35 may be remotely controlled in the manner shown in'Figure 1, or in any conventional manner, and a suitable alternating current relay responsive to current in the power lines |36 may be substituted for the direct current relay |46 in the direct current circuit. This substitution of the alternating current relay ls shown in Figure 12, where a current-responsive, time-delay relay |5| is shown controlling the circuit of the solenoid |52 through the wires |53 and |54 connected to the power lines,

While I have shown particular embodiments of my invention, it will, of course, be understood that I do not wish to be limited thereto, since many modifications may be made, and I therefore, contemplate by the appended claims to cover all such modifications as fall within the true spirit and scope of my invention.

I claim as my invention:

l. In combination, a Contact prod, an auxiliary switch on said prod, an abutment of conducting material engageable by said prod, a source of alternating current, rectifier means, a first circuit means connecting said rectifier means with said prod and said abutment of conducting material to pass current therethrough through said prod, a second circuit means connecting said rectier means with said source for energization thereby, a main switch in circuit connection with said second circuit means, motor means connected to operate said main switch, a third circuit means connecting said auxiliary switch with said motor means for the energization of said motor means, an impedance, and timing means operably connected with said third circuit to automatically insert said impedance in said second circuit means.

2. In combination, an abutment member of conducting material, a source oi direct current, a charged condenser, a contact prod, a transformer having one winding in a rst circuit with said source and said prod and said abutment to pass current through said abutment member, said transformer having a second winding in a second circuitJ with said condenser, and switch means on said prod in circuit connection with said second circuit and operable to eiiect the discharging oi said condenser through said second winding.

3. In combination, an abutment member of Conducting material, a source of direct current, a charged condenser, a transformer having on.l winding in a first circuit with said source and said prod and eonnectible to said abutment member to pass current therethrough, said transformer having a second winding in a second circuit with said condenser, and switch means in said second circuit and responsive to current in said nrst circuit to effect the discharging of said condenser through said second winding.

4. In the magnetic testing of engineering materials including sending current through a specimen of the material, in combination, a specimen to be tested, a first source of direct current, circuit means connecting said first source with said specimen to .pass current therethrough, a second source of direct current, means responsive to current in said circuit means, and means controlled by said last-named means for connecting said second source in aiding `connection with said rst source for a predetermined period of time thereby to increase the current ilowing through said specimen for said predetermined period of time.

5. In the magnetic testing of engineering materials including sending current through a specimen of the material, in combination, a rst source of direct current, a contact prod, a, specimen of the material to be tested, circuit means connecting said first source and said prod with said specimen to pass current therethrough, said contact prod including a contact rod, switch means, and switch actuating means arranged for movement relative to said rod, a second source of direct current, andmeans in circuit with said switch means operable to connect said second source in aiding connection with said first source.

6. In the magnetic testing of engineering materials including sending current through' a specimen of the material, in combination, a iirst source of direct current, a contactl prod, a specimen of the material to be tested, circuit means connecting said rst source and said prod with said specimen to pass current therethrough, a

second source of direct current, and switch means on said prod connected with means operable to connect said second source in aiding connection with said rst source.

7. In combination, a contact prod, an auxiliary switch on said contact prod, an abutment member of conducting material engageable by said prod, a source of direct current, circuit means including said source and said prod and said abutment member for passing current from said source through said ,abutment member, an impedance, timing means in circuit connection with said auxiliary switch, and means controlled by said timing means for inserting said impedance in said circuit means after a predetermined period of passing current through said abutment member without said impedance in said circuit.

JOHN E. CLARKE.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS Number Name Date 2,240,812 Sparrow May 6, 1941 1,899,000 Johnson Feb. 28, 1933 2,119.220 Scruggs May 31, 1938 1,955 967 Leathers Apr. 24, 1934 2,155,413 Eckman Apr. 25, 1939 2,245,920 Jardine et al June 17, 1941 2,221,576 Dawson Nov. 12, 1940 2,277,431 Fitch T Mar. 24, 1942 2,217,733 De Forest' Oct. 15, 1940 2,136,375 De Forest Nov. 15, 1938 Re. 19,611 De Forest June 18, 1935 254,948 Fox Mar. 14, 1882 844,090 Bijur Feb. 12, 1907 s 861,155 Achard July 23, 1907 

